Operation; Gearcase Removal - Polaris 2007 SPORTSMAN X2 800 Service Manual

FINAL DRIVE

Operation

Engaging front gearcase: The AWD switch may be turned on
or off while the vehicle is moving. AWD will not enable until
the engine rpm is below 3100 RPM. Once enabled, the AWD
remains engaged while the front gearcase is moving and will not
disengage until the rear wheels regain traction.
Engage the AWD switch before getting into conditions where
the front wheel drive may be needed. If the rear wheels are
spinning , release the throttle before switching to AWD.
CAUTION
Switching to AWD while the rear wheels are
spinning may cause severe drive shaft and
gearcase damage. Always switch to AWD while the
rear wheels have traction or are at rest.
With the AWD switch off the vehicle drives only the rear wheels
(2 wheel drive). When the AWD switch is activated it engages
the hilliard, locking both front axles into all wheel drive when
there is a loss of rear wheel traction.
Roll Cage Output Hubs
Ring Gear
4x4 Engagement: When the AWD switch is activated, a 12 Vdc
current charges the central coil, creating a magnetic field. This
magnetic field attracts an armature plate keyed to a roller cage
that contains 14 rollers and roller cam. The difference in rpm
between the input shaft and front axles forces the rollers up the
external cam. The rollers engage, or "wedge" themselves
between the pinion gear and output hubs that link both front
axles, resulting in true all wheel drive.
7.12
Ring Gear
If the rear wheels are spinning, release the throttle
engaged while the wheels are spinning, severe
Armature Plate Disengagement: As the front and rear wheels gain equal
traction, rotating very close to the same speed, the transmission
shaft "overdrives" the front gearcase input. The rollers are
forced outward, disengaging the AWD. The vehicle is now back
to rear wheel drive until the next loss of rear wheel traction.

Gearcase Removal

1. Stop engine, place machine in Park and set parking brake.
2. Loosen left front wheel nuts slightly.
3. Elevate the machine until the front wheels are off the
ground and support machine under footrest/frame area.
Magnetic Coil
Serious injury may result if machine tips or falls. Be
4. Remove left wheel nuts and wheel.
CAUTION
before turning the AWD switch on. If AWD is
drive shaft and clutch damage could result.
CAUTION
sure machine is secure before beginning this
service procedure. Wear eye protection when
removing and installing bearings and seals.
Rollers
Roll Cage